Additive manufacturing system for joining and surface overlay

ABSTRACT

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and is a continuation of,co-pending U.S. application Ser. No. 14/328,449, entitled “ADDITIVEMANUFACTURING SYSTEM FOR JOINING AND SURFACE OVERLAY,” having a filingdate of Jul. 10, 2014, which claims priority from and the benefit ofU.S. Provisional Application Ser. No. 61/846,935, entitled “ADDITIVEMANUFACTURING SYSTEM FOR JOINING AND SURFACE OVERLAY,” filed Jul. 16,2013, both of which are hereby incorporated by reference in theirentirety for all purposes.

BACKGROUND

The invention relates generally to additive manufacturing, and moreparticularly, to additive manufacturing anchors for joining differentmaterials and for forming surface overlays.

Various manufactured products may incorporate components with differentmaterials. As may be appreciated, the different materials of themanufactured products may be joined together by fasteners, matinggeometries, welding, or other processes. Fasteners or complementarygeometries may add components or weight to the joint. Heat input fromwelding components together may form a heat affected zone (HAZ) thataffects properties of the joint, such as the strength or fatigue life.Undesirable phases or intermetallic structures may form from mixingincompatible base materials into a weld. Direct manufacturing (DM)processes may build up materials with an electron beam in a vacuumchamber. However, the vacuum chamber and electron beam may reduce theavailability of DM processes for some products.

BRIEF DESCRIPTION

Certain aspects commensurate in scope with the originally claimedinvention are set forth below. It should be understood that theseaspects are presented merely to provide the reader with a brief summaryof certain forms the invention might take and that these aspects are notintended to limit the scope of the invention. Indeed, the invention mayencompass a variety of aspects that may not be set forth below.

In one embodiment, an additive manufacturing system includes an additivemanufacturing tool configured to receive a plurality of metallicanchoring materials and to supply a plurality of droplets to a part, anda controller configured to independently control the composition,formation, and application of each droplet to the plurality of dropletsto the part. The plurality of droplets is configured to build up thepart. Each droplet of the plurality of droplets includes at least onemetallic anchoring material of the plurality of metallic anchoringmaterials.

In another embodiment, a method of additively forming a part includesforming a plurality of droplets, wherein forming the plurality ofdroplets includes controlling a composition of each droplet of theplurality of droplets based at least in part on a desired compositionfor a respective desired deposition location of the part, and thecomposition of each droplet includes at least one of a plurality ofmetallic anchoring materials. The method also includes controllingheating of a first work piece, controlling heating of each dropletindependent of heating of the first work piece, and forming the part onthe first work piece. Forming the part includes applying each droplet atthe respective desired deposition location on the first work piece basedat least in part on the desired composition of the part. The heating ofthe first work piece, the heating of each droplet, and the respectivedesired deposition locations are based at least in part on apredetermined set of instructions.

In another embodiment, an additive manufacturing system includes one ormore feeders, a welding torch, and a controller. The one or more feedersare configured to supply a plurality of metallic anchoring materials toa welding torch. The welding torch is configured build up a part with aplurality of micro-deposits, wherein the welding torch is configured toform each micro-deposit of the plurality of micro-deposits from arespective droplet, and the respective droplet includes one or moremetallic anchoring materials of the plurality of metallic anchoringmaterials. The controller is configured to control the composition ofthe respective droplet of each micro-deposit of the plurality ofmicro-deposits.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a diagram of an embodiment of an additive manufacturing systemand a part;

FIG. 2 is a diagram of an embodiment of the additive manufacturingsystem and a part;

FIG. 3 is a diagram of an embodiment of the additive manufacturingsystem with an integrated tool head;

FIG. 4 is a diagram of an embodiment of a joint between differentmaterials formed by the additive manufacturing system of FIG. 1;

FIG. 5 is a chart illustrating an exemplary material composition of ajoint formed by the additive manufacturing system of FIG. 1;

FIG. 6 is a cross-section of an embodiment of a joint between differentmaterials formed by the additive manufacturing system of FIG. 1;

FIG. 7 is a cross-section of an embodiment of a joint between differentmaterials formed by the additive manufacturing system of FIG. 1;

FIG. 8 is a cross-section of an embodiment of a joint between differentmaterials formed by the additive manufacturing system of FIG. 1; and

FIG. 9 is a flow chart of an embodiment for a method of additivelyforming a part.

DETAILED DESCRIPTION

One or more specific embodiments of the present invention will bedescribed below. In an effort to provide a concise description of theseembodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in thedevelopment of any such actual implementation, as in any engineering ordesign project, numerous implementation-specific decisions must be madeto achieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

Turning to FIG. 1, an embodiment of an additive manufacturing system 10additively forms (e.g., prints, builds) a part 12 from one or moreanchoring materials 22. The additively formed part 12 may be a firstwork piece 14, a second work piece 16, or a joint between the first workpiece 14 and the second work piece 16, or any combination thereof. Insome embodiments, the first and second work pieces 14, 16 may be ofdifferent materials having significantly different physical properties.For example, in one embodiment, the first work piece 14 may be aluminumand the second work piece 16 may be steel. An additive manufacturingtool 18 deposits multiple droplets 20 to form (e.g., print, build) thepart 12 of the one or more anchoring materials 22. In some embodiments,the additive manufacturing tool 18 deposits the droplets 20 between thefirst and second work pieces 14, 16. As described in detail below, theadditive manufacturing tool 18 may utilize one or more types of energyto form and deposit the droplets 20 to form the part 12. The one or moretypes of energy utilized by the additive manufacturing tool 18 mayinclude, but are not limited to, an electric power output, photonicenergy (e.g., laser), or any combination thereof. Where the part 12 is ajoint between the first and second work pieces 14, 16, the additivemanufacturing tool 18 utilizes the energy to join the first and secondwork pieces 14, 16 via the part 12.

The additive manufacturing tool 18 heats the one or more anchormaterials 22 from a feeder 24 to form the droplets 20 having a desiredcomposition. In some embodiments, a mixer 31 of the additivemanufacturing tool 18 is configured to receive and to combine the one ormore anchor materials 22 from the feeder 24. For example, the mixer 31may combine the multiple anchor materials 22 into an electrode 32 havinga desired combination of the anchor materials 22. In some embodiments,the mixer 31 may form a powder mixture of the multiple anchor materials22. The electrode 32 and/or the powder mixture may be formed intodroplets 20. The one or more anchor materials 22 are metallic materialsthat include, but are not limited, to aluminum alloys, steel alloys,aluminum, iron, copper, manganese, silicon, magnesium, zinc, chromium,titanium, molybdenum, and nickel. As discussed herein, the droplets 20are units of material transfer. Each droplet 20 may become a“micro-deposit” when solidified, and the part 12 is formed from multiplemicro-deposits 21. FIG. 2 illustrates an embodiment of the additivemanufacturing tool 18 that directs the anchor material 22 (e.g.,electrode 32) into a molten puddle 23 of micro-deposits 21 to form thepart 12. The anchor material 22 may be at approximately ambienttemperature or a preheated temperature when inserted into the puddle 23.A portion 25 (e.g., ball) of the anchor material 22 is melted by thepuddle 23, thereby forming a micro-deposit 21 of the part 12 withoutforming a defined droplet 20. For example, the preheated portion 25 ofthe anchor material 22 may join the puddle 23, thereby forming themicro-deposit 21 of the part 12 via a hot-wire welding process. As maybe appreciated, the puddle 23 may be a recently formed section of thepart 12 that has not yet solidified. The energy applied to the puddle 23melt the portion 25 may include, but is not limited, to resistanceheating, photonic (laser) energy, or inductive heating.

Returning to FIG. 1, the one or more anchor materials 22 may include,but are not limited to, powders, solid wires, cored wires, tubularwires, or coated wires, or any combination thereof. In some embodiments,a first anchor material 26 may be substantially the material of thefirst work piece 14, and a second anchor material 28 may besubstantially the material of the second work piece 16. In other words,the first and second anchor materials 26, 28 may have chemicalcompositions that are substantially similar or compatible to therespective first and second work pieces 14, 16. For example, the firstanchor material 26 may have only minor differences (e.g., elementalcomponents varying by only fractions of compositional percentages,different alloys from the same alloy family) relative to the material ofthe first work piece 14. In some embodiments, anchoring materials 22 mayinclude, but are not limited to, brazing or soldering materials withlower melting temperatures than the materials of the first work piece 14and/or the second work piece 16. Anchor materials 22 with a lowermelting temperature than the first or second work pieces 14, 16 mayenable layers of micro-deposits 21 adjacent to the first or secondmaterials 14, 16 to not melt when the one or more anchoring materials 22is applied. Some embodiments of the additive manufacturing system 10 mayinclude more than two anchoring materials 22, such as 3, 4, 5, 6, 7, 8,9, 10, or more anchoring materials 22. For example, a third anchormaterial 29 may be supplied to the additive manufacturing tool 18. Thethird anchor material 29 may have a chemical composition that issubstantially similar to the material of the first work piece 14 or tothe material of the second work piece 16. Additionally, or in thealternative, the third anchor material 29 may have a chemicalcomposition that is an alloying material that provides a desiredproperty (e.g., adhesion, increased or decreased fluidity) between thefirst and second anchoring materials 26, 28, and/or the chemicalcomposition of the third anchor material 29 may provide a desiredproperty (e.g., strength, hardness, galvanic protection) to the part 12.

A controller 30 of the additive manufacturing system 10 controls theapplication of the droplets 20 to form the part (e.g., anchor) 12 fromthe micro-deposits 21. In some embodiments with wired anchor materials22, the controller 30 controls the composition of the droplets 20applied to the part 12 by adjusting the relative quantities of the oneor more anchor materials 22 supplied to the mixer 31 of the additivemanufacturing tool 18, which thereby forms the electrode 32. Forexample, where the first anchor material 26 is substantially similar toor compatible with the material of the first work piece, the controller30 may increase the relative ratio of the first anchor material 26 inthe electrode 32 to form (e.g., print) portions of the part 12 near thefirst work piece 14. As discussed herein, the composition of eachdroplet 20 is based on the one or more anchor materials 22 that make upthe respective droplet 20. The droplets 20 are liquid (e.g., molten) atleast in part. In some embodiments, a droplet 20 may be a liquid anchormaterial 22 encapsulating a solid element of the same or a differentanchor material 22. For example, the additive manufacturing tool 18 mayat least partially melt only an outer layer of a droplet 20.

The additive manufacturing tool 18 may mix (e.g., melts, sinters,compresses) multiple anchor materials 22 with the mixer 31 into anelectrode 32 with a mixed composition. The controller 30 may control theadditive manufacturing tool 18 to form droplets 20 with the mixedcomposition from the mixed electrode 32. The controller 30 may adjustthe composition of the part (e.g., anchor) 12 by varying ratios of theone or more anchor materials 22 in the mixed electrode 32. In someembodiments, the additive manufacturing tool 18 supplies each of the oneor more anchor materials 22 as a separate electrode 32 that the additivemanufacturing tool 18 respectively forms into droplets 20. For example,the controller 30 may control the additive manufacturing tool 18 to formseparate droplets 20 with different respective compositions from each ofthe multiple electrodes 32. The controller 30 may adjust the compositionof the part 12 by varying ratios of the one or more anchor materials 22applied as droplets 20 to the part 12.

In some embodiments, the controller 30 is coupled to multiple additivemanufacturing tools 18, each supplying a separate anchor material 22 viaa respective electrode. The controller 30 may control each of themultiple additive manufacturing tools 18 to adjust the composition ofthe part 12 by varying ratios of the anchor materials 22 supplied asdroplets 20 by each additive manufacturing tool 18. As illustrated inFIG. 3, multiple wire delivery systems (e.g., feeders 24) may becombined an integrated tool head 33 of the manufacturing tool to supplymultiple anchor materials 22 in rows or a grid. The integrated tool head33 may increase the deposition rate of the anchor materials 22 to form(e.g., print, build up) the part 12. The integrated tool head 33 of theadditive manufacturing tool 18 may have multiple mixers 31 to receiveand process the anchor materials 22 into electrodes 32 and/or powderstreams. The controller 30 may control each mixer 31 so that eachelectrode 32 and/or powder stream has the same composition. In someembodiments, the controller 30 controls one or more mixers 31 so thatthe respective electrode 32 or powder stream has a different compositionthan the electrode 32 or powder stream from another mixer 31. Theintegrated tool head 33 may enable the additive manufacturing tool 18 toform multiple layers 35 of the part at approximately the same time,thereby enabling a reduction of production time for the part 12 byreducing a quantity of passes of the additive manufacturing tool 18 toform the part 12. A first layer 37 of the part 12 formed ofsubstantially solidified micro-deposits 21 is illustrated with a grid39. The micro-deposits 21 of a second layer 41 of the part 12 formedbetween the first layer 37 and a third layer 43 may be less solidifiedthan the micro-deposits 21 of the first layer 37, yet sufficientlysolidified to support and bond with the deposited droplets 20 of thethird layer 43. The controller 30 controls the deposition rate of thedroplets 20 and the rate of formation of the layers 35 by the additivemanufacturing tool 18 to enable each layer to bond with the previouslyformed layer 35. For example, the controller 30 may decrease thedeposition rate or rate of layer formation as the additive manufacturingtool 18 builds up the part 12.

Returning again to FIG. 1, the controller 30 controls a power source 34to adjust the power output (e.g., current output, voltage output,photonic energy) provided to the additive manufacturing tool 18 to meltthe one or more anchor materials 22 into the droplets 20. As may beappreciated, the power source 34 may include, but is not limited to, anengine-driven generator, a welding power supply, an inverter, laser, orany combination thereof. The controller 30 may control the power source34 to provide a DC or AC power output to the electrode 32 in acontrolled waveform, similar to a pulsed welding process or a shortcircuit welding process (e.g., regulated metal deposition (RMD™)). Insome embodiments, the controller 30 controls the power source 34 toprovide power output to the electrode 32 via the additive manufacturingtool 18 to enable a modified short circuit welding process (e.g.,controlled short circuit) to form the part 12. Additionally, thecontroller 30 facilitates formation of the part 12 by controlling theadditive manufacturing tool 18 to extend and retract the one or moreelectrodes 32 during a controlled short circuit welding process. Thepower output provided to the additive manufacturing tool 18 melts theelectrode 32 into the droplets 20, which are deposited via the arc tothe part 12 as micro-deposits 21. That is, in some embodiments, theelectrode 32 is a welding wire, the additive manufacturing tool 18 is awelding torch configured for a pulsed welding process or a short circuitwelding process, and the feeder 24 is a welding wire feeder. The weldingtorch may layer micro-deposits 21 via the arc, thereby forming (e.g.,building up, printing) the part 12 from welding wire via a pulsedwelding process and/or a short circuit welding process (e.g., RMD). Asmay be appreciated, some embodiments of the additive manufacturingsystem 10 may include a gas supply 45 configured to provide one or moreshielding gases to the additive manufacturing tool 18. The one or moreshielding gases may include, but are not limited to, argon, carbondioxide, helium, nitrogen, hydrogen, and combinations thereof.

As discussed above, the controller 30 may control power output forprocesses utilizing electrical arc and/or photonic energy to heat theelectrode 32. The controller 30 may control the rate at which thedroplets 20 are applied to the part 12 by controlling the power source34. In some embodiments, the controller 30 controls a heating device 36(e.g., inductor coil, resistive heater) to preheat the electrode 32.Accordingly, the controller 30 may control the heat applied to theelectrode 32 to form the droplets 20. Additionally, or in thealternative, the heating devices 36, 42, 44 may enable pre-heating orpost-heating of the electrode 32, the first work piece 14, and/or thesecond work piece 16 respectively. Preheating the electrode 32 mayreduce the heat applied to the first and second work pieces 14, 16,thereby reducing the formation of a heat affected zone

The droplets 20 added to the part 12 as micro-deposits 21 affect theheat added to the first work piece 14 and the second work piece 16. Asdiscussed herein, the formation of the micro-deposits 21 may include,but is not limited to, heating the anchor material 22 (e.g., electrode32) to form the droplet 20, and cooling the micro-deposit 21 in the part12. As may be appreciated, the heat of the droplet 20 and the coolingrate of the micro-deposit may affect the microstructure of themicro-deposit 21 formed by the respective droplet 20, thereby affectingthe properties of the part 12. For example, the microstructure of themicro-deposits 21 of the part 12 at a first location 38 may be differentthan the microstructure of the micro-deposits 21 at a second location40. Additionally, as discussed herein, the application of each droplet20 to the part 12 may include, but is not limited to, the applicationrate of droplets 20 to the part 12 and the application location on thepart 12 of each micro-deposit 21. The controller 30 may control thetemperature of the droplets 20, the application (e.g., deposition) rate,and the application location of each droplet 20 to control the heatapplied to the work pieces 14, 16. For example, the controller 30 mayreduce the inducement of a heat affected zone (HAZ) that may affect themicrostructure and properties (e.g., strength, fatigue life) of the workpieces 14, 16 proximate to the part 12. The temperature, depositionrate, and application location of the droplets 20 in the part 12 affectsthe heat added to the first work piece 14 and the second work piece 16.For example, an arc at 2000° C. adds more heat to the part 12 than anarc at 1200° C. As may be appreciated, high deposition rates (e.g., 60Hz) of droplets 20 may add less heat to the part 12 than relativelylower deposition rates (e.g., 30 Hz) of droplets 20. Additionally,droplets 20 applied at the first location 38 on the first work piece 14add more heat to the first work piece 14 than droplets 20 applied at thesecond location 40 on the first work piece 14. In some embodiments, thecontroller 30 controls the heating device 36 to affect the applicationtemperature of the micro-deposits 21 in the part 12 to affect the heatadded to the first work piece 14 and the second work piece 16. Thecontroller 30 may control the feeder 24 and/or the mixer 31 to controlthe application rate, and the controller 30 may control the power source34 to control the application rate and the application temperature ofthe droplets 20 as the micro-deposits in the part 12. In someembodiments, a robotic system 56 coupled to the additive manufacturingtool 18 may control the application location of the droplets 20 bymoving the additive manufacturing tool 18 along coordinate axes 48 viaone or more servomotors 57.

In a similar manner to controlling the heat applied to the work pieces14, 16, the controller 30 may control the temperature of the droplets20, the application rate, and the application location of each droplet20 to control the heat applied to previously applied micro-deposits 21.For example, the application rate and the temperature of the droplets 20may affect the cooling rate and microstructure of previously appliedmicro-deposits 21. The controller 30 may control the application rateand the temperature of the droplets 20 to achieve a desiredmicrostructure for each of the micro-deposits 21 utilized to form thepart 12. Accordingly, the controller may control the composition and/orthe microstructure of the micro-deposits 21 of the part 12.

In some embodiments, a first heating device 42 may heat the first workpiece 14 near the part 12, and/or a second heating device 44 may heatthe second work piece 16 near the part 12 (e.g., joint). The first andsecond heating devices 42, 44 may include, but are not limited to,inductor coils, resistance heaters, flames, and so forth. The first andsecond heating devices 42, 44 may interface with one or more surfaces ofthe respective first and second work pieces 14, 16. For example, thefirst heating device 42 may extend around the first work piece 14. Thecontroller 30 may control the first heating device 42 and/or the secondheating device 44 to preheat the respective work pieces 14, 16 near thepart 12. As may be appreciated, preheating a work piece 14, 16 mayaffect the adhesion to micro-deposits 21 from the additive manufacturingtool 18. For example, increasing the temperature of the first work piece14 may increase the adhesion of the micro-deposits 21 at the firstlocation 38. In some embodiments, the controller 30 independentlycontrols the first and second heating devices 42, 44, thereby enablingthe first work piece 14 to be preheated to a different temperature thanthe second work piece 16.

As discussed previously, the first work piece 14 may be different fromthe second work piece 16. For example, the first work piece 14 may bealuminum and the second work piece 16 may be steel. In some embodiments,the first and second work pieces 14, 16 may be the same or differentcompositions with the same base metal (e.g., aluminum, titanium, iron,galvanized-coated material, high strength steel). For example, the firstwork piece 14 may be a nickel coated steel, and the second work piece 16may be a relatively high-carbon steel. The first work piece 14 may havedifferent properties and/or structure than the second work piece 16. Forexample, the melting temperature, thermal conductivity, and strength,among other properties, may differ between the first work piece 14 andthe second work piece 16. Additionally, or in the alternative, the firstwork piece 14 and the second work piece 16 may have differentsensitivities to heat. For example, the first work piece 14 may beannealed at a melting temperature of the second work piece 16.Accordingly, annealing the first work piece 16 (e.g., by heating it tothe melting temperature of the second work piece 16) may affectproperties (e.g., strength, fatigue-life) of the first work piece 16.

As may be appreciated, the heat affected zone (HAZ) of a metal may bedefined herein as the area of the metal in which the properties and/ormicrostructure of the metal has been affected by heat. In someembodiments, the controller 30 may independently control the heatapplied to the electrode 32, the heat applied to the first work piece 14(e.g., via the first heating device 42), and the heat applied to thesecond work piece 16 (e.g., via the second heating device 44). Throughindependent control of the heat applied to these components, theadditive manufacturing system 10 may reduce the HAZ of the first workpiece 14 and/or the second work piece 16. For example, if the first workpiece 14 is aluminum and the second work piece 16 is a steel with ahigher melting temperature than the first work piece 14, the controller30 may control the additive manufacturing tool 18 to apply the droplets20 near the second work piece 16 (e.g., steel) with more heat and/or ata higher rate than the droplets 20 near the first work piece 14 (e.g.,aluminum).

The controller 30 may control the composition and the formation of eachof the droplets 20 applied to build the part 12 with micro-deposits 21as the additive manufacturing tool 18 moves between the first work piece14 and the second work piece 16. In this way, the additive manufacturingsystem 10 may control the composition and structure (e.g., spatialdistribution of the micro-deposits 21) of the part 12 to have a desiredset of properties while controlling the HAZ of the first and/or secondwork pieces 14, 16. Sensors 46 may measure the temperature and coolingrate of the electrode 32, the first work piece 14, and/or the secondwork piece 16. Feedback from the sensors 46 may be stored as temperaturehistory of the electrode 32, the first work piece 14, and/or the secondwork piece 16. The controller 30 may use this temperature history tocontrol the composition and structure of the part 12. In someembodiments, the sensors 46 may measure the position of the additivemanufacturing tool 18, first work piece 14, and second work piece 16relative to the set of coordinate axes 48. The controller 30 may controlthe application of the droplets 20 to the part 12 based at least in parton the relative distance from the first work piece 14 and/or the secondwork piece 16. For example, in some applications the part 12 may beformed to have a gradient composition of the first and second anchormaterials 26, 28, such that the composition of the part 12 adjacent tothe first work piece 14 is compatible (e.g., forming a strong bond) withthe first work piece 14, and the composition of the part 12 adjacent tothe second work piece 16 is compatible (e.g., forming a strong bond)with the second work piece 16.

The controller 30 may independently control the thermal cycle, peaktemperature, and cooling rates of each of the micro-deposits 21 based atleast in part on the application location in the part 12. The controller30 may independently control the composition and the formation of eachof the droplets 20 for the application location according to a set ofinstructions (e.g., code) executed by a processor 49. The processor 49may load the set of instructions from a memory 50 based at least in parton the work pieces 14, 16 and the anchor materials 22. In someembodiments, an operator (e.g., host computer) may provide the set ofinstructions directly to the controller 30 via an operator interface 52.For example, the operator may load a set of instructions for forming thepart 12 from a three-dimensional model (e.g., computer aided design(CAD) model) of the anchor produced by a three-dimensional 3D CAD tool.In some embodiments, the controller 30 may receive and/or produce a setof instructions to produce the part 12 with a desired composition ofanchor materials 22. For example, the controller 30 may utilize a 3D CADmodel of the part 12 to control the robotic system 56 to produce thepart 12 from the anchor materials 22. Additionally, or in thealternative, an operator may input information about the work pieces 14,16 and the anchor materials 22 into the operator interface 52, and thecontroller 30 may determine and/or modify the set of instructions toform the part 12 with desired characteristics. The set of instructionsdirects the controller 30 to control the composition, formation, andapplication of each droplet 20 as a micro-deposit 21 to form the part 12with desired characteristics.

The controller 30 may use input from the sensors 46 to individuallycontrol each droplet 20 applied to the part 12 as a micro-deposit 21. Insome embodiments, the controller 30 may adapt the set of instructionsbased at least in part on the input from the sensors 46 to compensatefor changes to the first work piece 14, the second work piece 16, or thepart 12. For example, the controller 30 may adapt the applicationlocation and/or the heating of the droplets 20 during the formation ofthe part 12 if the input from the sensors 46 indicates a change in thefit-up of a joint between the first work piece 14 and the second workpiece 16. Additionally, or in the alternative, the controller 30 mayadapt the application and/or the heating of the droplets if the inputfrom the sensors 46 indicates a deflection or burn through of the firstwork piece 14 and/or the second work piece 16. The controller 30 mayadapt the temperature of the first work piece 14 and/or the temperatureof the second work piece 16 (e.g., via the heating devices 42, 44)during the formation of the part 12 if the input from the sensors 46indicates a deflection or burn through of the first work piece 14 and/orthe second work piece 16.

The additive manufacturing system 10 may build the part 12 between thefirst work piece 14 and the second work piece 16 by manual or automaticmovement of the additive manufacturing tool 18. In some embodiments, thedroplets 20 may be deposited via the arc (e.g. spray) as shown inFIG. 1. In some embodiments as illustrated in FIG. 2, the electrode 32contacts the work piece and/or part 12, and the additive manufacturingtool 18 applies the respective micro-deposits 21 via short circuit. Insome embodiments, an operator begins or resumes building the part 12 byactuating a trigger 54. The controller 30 determines a location of theadditive manufacturing tool 18 relative to the work pieces 14, 16 viathe sensors 46, and the controller 30 determines the applicationlocation of the micro-deposits 21 prior to formation of the droplets 20of the desired composition according to the set of instructions. In someembodiments, the robotic system 56 controls the movement of the additivemanufacturing tool 18 along the coordinate axes 48, such as viaservomotors 57. The controller 30 may control the robotic system 56 withthe set of instructions to move the additive manufacturing tool 18 toapply the controlled droplets 20 as micro-deposits 21 to respectivelocations in the part 12 based on the set of instructions. The roboticsystem 56 thereby enables the controller 30 to automatically form parts12 with a desired composition and geometry. In some embodiments, therobotic system 56 may form (e.g., print, build up) the parts 12 from theone or more anchor materials 22 separate from the work pieces 14, 16.The formed parts 12 may later be joined with the work pieces 14, 16.

FIG. 4 illustrates an embodiment of a joint 60 that may be formed by theadditive manufacturing system 10 described above. The joint 60 hasmultiple layers 62 that connect the first work piece 14 to the secondwork piece 16. In some embodiments, the material of each layer 62 maydiffer from the adjacent layers 62. For example, the embodiment of thejoint 60 of FIG. 4 has seven layers (e.g., layers 62 a, 62 b, 62 c, 62d, 62 e, 62 f, 62 g) between the first work piece 14 and the second workpiece 16. The first layer 62 a may be a material more compatible withthe first work piece 14 than the second layer 62 b, or a solder or brazefiller that does not melt the first work piece 14. The seventh layer 62g may be a material more compatible with the second work piece 16 thanthe sixth layer 62 f, or a solder or braze filler that does not melt thesecond work piece 16. If the first work piece 14 is aluminum and thesecond work piece 16 is a steel alloy, the layers 62 in a firstdirection 64 may have progressively less aluminum or “aluminum-friendly”material, and the layers in a second direction 66 may have progressivelyless steel or “steel-friendly” material. As may be appreciated, a“friendly” anchoring material 22 may be a material that is substantiallythe same material as the base material and/or forms a bond of desiredstrength determined by the operator based on the joint. Additionally, orin the alternative, several layers with specific compositions andstructures based at least in part on the composition or microstructureof the respective first and second work pieces 14, 16 may transitionfrom the first work piece 14 to the second work piece 16. In someembodiments, the joint 60 may be formed with less than seven layers 62(e.g., 1, 2, 3, 4, 5, or 6 layers) of different compositions, or withmore than seven layers 62 (e.g., 8, 9, 10, 15, 20, or 50 or more layers)of different compositions.

In some embodiments, the first and/or second work pieces 14, 16 may havea coating 68, such as a corrosion resistant coating (e.g., zinc), wearresistant coating, and so forth. The controller 30 may control thecomposition and application of the layers 62 so that the joint 60 doesnot remove or substantially affect the coating 68 of a work pieceproximate to the joint 60. For example, if the second work piece 16 isgalvanized steel with a zinc coating 68, the seventh layer 62 g may havezinc or a “zinc-friendly” material (e.g., silicon bronze) as ananchoring material, and the droplets 20 for the seventh layer 62 g maybe applied without substantially removing, melting, or affecting thecorrosion-resistance of the zinc coating 68.

During application of the layers 62, the additive manufacturing system10 may independently control the application of heat to the work piecesand the joint 60 to reduce the melting and/or the HAZ from each layer62, as discussed above. In some embodiments, the controller 30 maycontrol the additive manufacturing system 10 so that the application ofthe interior layers (e.g., layers 62 b, 62 c, 62 d, 62 e, and 62 f) doesnot substantially produce an HAZ in the first work piece 14 and/or thesecond work piece 16. That is, only the first layer 62 a may heat and atleast partially fuse or bond with the first work piece 14, and/or onlythe seventh layer 62 g may heat and at least partially fuse or bond withthe second work piece 16. Additionally, or in the alternative, thecontroller 30 may control the penetration of the droplets 20 into thework piece 14, 16.

In some embodiments, the additive manufacturing system 10 may adjust thegeometry and composition of the layers 62 applied to build the joint 60.For example, a first end 70 of the first work piece 14 may have a firstwidth 72, and a second end 74 of the second work piece 16 may have asecond width 76 that is different from the first width 72. Thecontroller 30 may apply the droplets 20 as micro-deposits 21 to formlayers 62 that have widths between the first width 72 and the secondwidth 76. As may be appreciated, the controller 30 may form the joint 60with a geometry that provides a desired level of strength. For example,a curved geometry (e.g., fillet) or tapered geometry (as shown) of thejoint 60 may reduce stresses in the joint 60 relative to a perpendicularjoint geometry 60.

FIG. 5 illustrates a chart 80 of an exemplary joint composition betweenthe first work piece 14 and the second work piece 16. The controller 30may control the composition of each of the micro-deposits 21 forming thejoint 60, thereby controlling the properties (e.g., adhesion to workpiece, strength, corrosion resistance) of the joint 60. As discussedabove, in some embodiments the controller 30 may control the compositionof each of the droplets 20 via a mixed electrode 32. The mixed electrode32 may be formed from one or more anchoring materials 22. Thecomposition of each of the droplets may be controlled via controllingthe composition of the mixed electrode 32. That is, a droplet 20 may beformed of one or more anchor materials 22. Additionally, or in thealternative, the controller 30 controls the composition of each of thedroplets 20 via forming separate droplets from one or more electrodes32, where each of the one or more electrodes 32 may be a differentanchor material 22. The controller 30 may selectively control thecomposition of the joint 60 by controlling a ratio of the droplets 20from each electrode 32 applied to the joint 60. That is, each droplet 20may be a distinct anchor material 22, and the joint 60 is formed fromseparate micro-deposits 21 of different anchor materials 22 with desiredratios. The embodiment illustrated by chart 80 shows the percentcomposition 82 of the joint 60 with respect to the distance 84 from thefirst end 70 of the first work piece 14 to the second end 74 of thesecond work piece 16. The joint 60 of chart 80 has three anchoringmaterials 22: the first anchoring material 26, the second anchoringmaterial 28, and a third anchoring material 29 Some embodiments of thejoint 60 may have more or less than three anchoring materials 22.

The controller 30 controls the composition and/or location of each ofthe droplets 20 applied to the joint 60 as micro-deposits 21. At thefirst end 70, the joint 60 is substantially compatible with the firstwork piece 14 (e.g., the first anchoring material 26). In someembodiments, the material of the joint 60 at the first end 70 issubstantially the same as the material of the first work piece 14. Asthe distance 84 increases towards the second end 74 of the second workpiece 16, the percentage of the first anchoring material 26 in the joint60 decreases, and the percentage of the second anchoring material 28(e.g., the second work piece 16) increases. In some embodiments, thepercentage of the first anchoring material 26 in the joint 60 has aninverse relationship with the distance 84 from the first end 70, and thepercentage of the second anchoring material 28 in the joint 60 has adirect relationship with the distance 84 from the first end 70. In someembodiments, the material of the joint 60 at the second end 74 issubstantially the same as the material of the second work piece 16. Therelationships of the anchoring materials 22 in the joint 60 with respectto the distance 84 from the first end 70 may include, but are notlimited to, linear, exponential, logarithmic, or any combinationthereof. In some embodiments, the percentage of the first anchoringmaterial 26 in the joint 60 may be approximately equal to the percentageof the second anchoring material 28 at a middle portion 88 of the joint60. However, other embodiments of the joint 60 may have differentrelative percentages of the first anchoring material 26 and the secondanchoring material 28 throughout the joint 60. In some embodiments, thepercentage of the third anchoring material 29 in the joint 60 may begreater proximate to the first work piece 14 than proximate to thesecond work piece 16. For example, the third anchor material 29 mayaffect the adhesion or other properties of the first and second anchormaterials 26, 28 in layers 62 with a majority of the first anchormaterial 26. In some embodiments, the third anchor material 29 is morecompatible with the first anchor material 26 than the second anchormaterial 28. As may be appreciated, the additive manufacturing system 10may form each layer 62 of the joint 60 between the first and second workpieces 14, 16 with a variety of different compositions of anchoringmaterials 22.

While FIG. 5 illustrates a relatively gradual change of composition ofthe joint 60 between the first end 70 of the first work piece 14 and thesecond end 74 of the second work piece 16, some embodiments of the joint60 may include a step transition of composition. The transition for thejoint 60 may be selected based at least in part on the resultingmaterial properties (e.g., strength, thermal expansion) and/or economicfactors (e.g., material cost, manufacturing time, manufacturing cost).For example, the layer adjacent to the first end 70 may be primarily thefirst material 26, the layer adjacent to the second end 74 may beprimarily the second material 28, and the one or more layers between thefirst and second ends 74 may be primarily the third material 29.

FIG. 6 illustrates an embodiment of a joint 100 between the first workpiece 14 and the second work piece 16. In some embodiments, the additivemanufacturing system 10 may form the joint 100 with regions 102 havingdifferent compositions of anchoring materials 22 in place of, or inaddition to, the layers 62 described above with FIG. 2. The additivemanufacturing system 10 may determine the composition and geometry ofeach region 102 to provide the joint 100 with a desired set ofproperties. For example, non-linear regions 102 of varyingcross-sectional geometries may be more resistant to shear stresses onthe joint 100 than the joint 60 with multiple linear layers 62.

In some embodiments, connecting the first work piece 14 to the secondwork piece 16 may increase the corrosion potential if the work pieces14, 16 have different electric potentials. The additive manufacturingsystem 10 may deposit the anchoring materials 22 to provide galvanicprotection, thereby reducing the corrosion of the first and/or secondwork pieces 14, 16. For example, the additive manufacturing system 10may form a sacrificial anode 104 in the joint 100. In some embodiments,the sacrificial anode 104 may be the first anchoring material 26, thesecond anchoring material 28, or a third anchoring material 29. Theanchoring material of the sacrificial anode 104 may be a differentanchoring material than a remainder of the joint 100. As may beappreciated, the sacrificial anode 104 formed in the joint 100 mayprovide corrosion protection to the first and/or second work pieces 14,16, and/or the structural load bearing portion of the joint 100.

FIG. 7 illustrates an embodiment of the part 12 in a joint 105 (e.g.,lap joint) between the first and second work pieces 14, 16. The firstwork piece 14 may have a first recess 106, and a second recess 107(e.g., hole) of the second work piece 16 may be positioned near thefirst recess 106. The first recess 106 and the second recess 107 may ormay not have the same shape. For example, the first recess 106 may be achannel in a top surface 108 of the first material 14, and the secondrecess 107 may be a hole through the second material 16. In someembodiments, the first work piece 14 may not have the first recess 106,and only the second material 16 has the second recess 107. The additivemanufacturing system 10 may form the part 12 (e.g., printed fastener) bylayering micro-deposits 21 to build up (e.g., print) the one or moreanchoring materials 22 through the second material 16 in the directionshown by arrow 109. In some embodiments, the part 12 has a layeredstructure similar to the joint 60 of FIG. 4, or the part 12 has thenon-linear structure similar to the joint 100 of FIG. 6. Moreover, thepart 12 may be formed (e.g., printed) from one anchoring material 22,such as an anchoring material (e.g., aluminum) that is the same orcompatible material with the material (e.g., aluminum alloy) of thefirst work piece 14.

FIG. 8 illustrates a cross-sectional view of an embodiment of the part12 between the first and second work pieces 14, 16. In some embodiments,the part 12 may be a lap joint 105, a T-joint, butt joint, corner joint,or edge joint between the first and second work pieces 14, 16. In someembodiments, the part 12 is a plug coupled (e.g., fused) to the firstwork piece 14 within the second recess 107 (e.g., slot, hole) of thesecond work piece 16. The additive manufacturing system 10 may form thepart 12 by layering micro-deposits 21 on the first work piece 14 andwithin the second recess 107 of the second work piece 16, where theanchor material 22 used for the part 12 is substantially the first workpiece 14 and/or an anchoring material “friendly” to the first work piece14. For example, the additive manufacturing system 10 may additivelyform (e.g., build up, print) an aluminum part 12 on an aluminum firstwork piece 14 and within a second recess 107 of a steel second workpiece 16. The part 12 may be integrally formed (e.g., welded, fused, ormelted) with the first work piece 14 by the additive manufacturing tool18, but not welded, fused, or melted with the second work piece 16. Thepart 12 may be built up (e.g., printed, additively manufactured) to thefirst work piece 14 to form a mating geometry to interface with thesecond work piece 16. That is, the part 12 may merely interface with atleast a portion of the second recess 107 of the second work piece 16rather than fusing with a portion of the second recess 107. The additivematerial 22 of the part 12 may not penetrate the surface of the secondwork piece 16. In this way, the part 12 may join the first work piece 14to the second work piece 16 without melting the second work piece 16 ofthe second recess 107, thereby reducing the energy used to join thefirst work piece 14 to the second work piece 16. Accordingly, the part12 may resist shear forces between the first and the second work pieces14, 16 across the joint 105 as shown by the arrows 113. In someembodiments, the additive manufacturing system 10 may form a flange 111on the part 12 that retains the interface between the first and secondwork pieces 14, 16. The flange 111 may be a cap that resists separatingforces (e.g., arrows 115) between the first and the second work pieces14, 16.

In some embodiments, the additive manufacturing tool 18 may form (e.g.,build up, print) parts to form joints between coated components. Forexample, a joint portion (e.g., end portion) of the second work piece 16(e.g., steel) may be coated, brazed, and/or clad with the first workpiece 14 (e.g., aluminum). In some embodiments, the additivemanufacturing tool 18 may additively form the coating of the first workpiece 14 on the second work piece 16. The additive manufacturing tool 18may build up the part 12 by integrally forming (e.g., printing, welding,melting, fusing) the additive anchoring material 22 to the coating ofthe first work piece 14. In some embodiments, the additive manufacturingtool 18 integrally forms the part 12 with the coating of the first workpiece 14 and with another component of the same material as the coating.For example, the additive manufacturing tool 18 may be used to form analuminum anchor on an aluminum-coated steel work piece, where thealuminum anchor is fused with an aluminum component. In someembodiments, the additive manufacturing tool 18 integrally forms thepart with the coating of a work piece (e.g., first work piece 14), wherethe printed part 12 interfaces (e.g., mates) with another work piece(e.g., the second work piece 16) of the material different from thecoating, like the part 12 shown in FIG. 8. For example, the additivemanufacturing tool 18 may be used to form an aluminum part (e.g.,fastener) on an aluminum-coated steel component, where the aluminum partinterfaces with a recess (e.g., hole) of a steel component. As may beappreciated, aluminum melts at a lower temperature than steel.Accordingly, forming an aluminum part on an aluminum-coated steelenables a joint to be formed between the aluminum-coated steel componentand another component (e.g., steel, aluminum, etc.) without meltingsteel of the joint. Integrally forming the part 12 with the coating mayreduce the energy used to join different materials.

FIG. 9 illustrates an embodiment of a method 110 for the additivemanufacturing system 10 to form the part 12, where the part 12 is ajoint (e.g., anchor) between the first work piece 14 and the second workpiece 16. The work pieces 14, 16 are first fit up (block 112) for thejoint. An operator may input (block 114) the part information into theadditive manufacturing system 10, such as via the operator interface 52.For example, the operator may input one or more of the material of thefirst work piece 14, the material of the second work piece 16, theavailable anchoring materials 22, the type of joint (e.g., butt, lap,tee, edge, corner), and the joint geometry. The controller 30 loads(block 116) instructions for the part 12 (e.g., joint) based at least inpart on the supplied part information. In some embodiments, theinstructions are robotic instructions produced by an offline programmingtool. The instructions may be based at least in part on a 3D model ofthe part 12 produced by a CAD tool. The controller 30 may utilize therobotic system 56 to form the part 12.

The controller 30 controls the formation and application of each droplet20 to form the part (e.g., joint) between the work pieces 14, 16 withmicro-deposits 21. Prior to deposition of each droplet 20, thecontroller 30 determines (block 118) the deposition location for thedroplet 20 as the micro-deposits 21. The deposition location may bedirectly on one of the work pieces and/or on a previous micro-deposit21. The controller 30 selects (block 120) the one or more anchormaterials 22 used to form the droplet 20. As described above, one ormore anchor materials 22 may be provided to the additive manufacturingtool 18 as a one or more electrodes 32 in wired or powdered forms basedat least in part on the loaded instructions. In some embodiments theadditive manufacturing tool 18 may mix (e.g., melt, sinter, compress)multiple anchor materials 22 into a mixed electrode 32 or a mixedpowder, which is formed into droplets 20. In some embodiments, theadditive manufacturing tool 18 may have multiple electrodes 32 ofdifferent anchoring materials 22. The controller 30 selects (block 120)which electrode 32 to form the droplet 20 based at least in part on theloaded instructions. The controller 30 may direct the additivemanufacturing tool 18 to heat the electrode 32 to form a droplet 20 andcontrols (block 122) the heating of the droplet 20 to be applied to formthe part 12. The controller 30 controls the heating of the droplet 20via controlling the power output supplied to the electrode 32 for thearc. In some embodiments, the controller 30 controls preheating of theelectrode 32, such as via an induction heater, resistance heater, and/orlaser in or around the additive manufacturing tool 18.

The controller 30 may control (block 124) the heating of the work piecesindependent from controlling (block 122) the heating of the anchoringmaterials 22. Heating devices 42, 44 on the first and/or the second workpieces 14, 16 may be controlled to preheat the respective material 14,16 proximate to the part (e.g., joint). The controller 30 controls theadditive manufacturing system 10 to apply (block 126) the droplet 20with the desired composition at the determined deposition location whenthe work piece is at the desired temperature. After the droplet 20 isdeposited as a micro-deposit 21, the controller 30 may receive andevaluate (block 128) sensor inputs regarding components of the additivemanufacturing system 10. For example, the controller 30 may determinethe respective temperature histories and/or relative locations of thework pieces and the part from the sensors 46. Based at least in part onthe sensor inputs, the controller 30 may adapt (block 130) the set ofinstructions for position changes of the work pieces and/or of the part,such as due to thermal effects. In some embodiments, the controller 30may increase the deposition rate of the droplets 20 utilized to form thepart to reduce the heat input to the work pieces 14, 16. The controller30 or operator may move (block 132) the additive manufacturing tool 18and repeat blocks 118-128 until the part (e.g., joint) is complete.

While some of the embodiments described above utilize the additivemanufacturing system 10 to form a joint between a first work piece 14 ofa first material and a second work piece 16 of a second material withone or more anchoring materials 22, it will be appreciated that theadditive manufacturing system 10 may build the first work piece from afirst anchoring material and/or may build the second work piece from asecond anchoring material. That is, the additive manufacturing system 10may build up (e.g., print) a component, such as a work piece, with oneor more anchoring materials 22 without forming the joint at the sametime. For example, the additive manufacturing system 10 may build up thefirst work piece 14 in a first direct manufacturing (DM) process, buildup the second work piece 16 in a second DM process, and build up a part(e.g., joint) between the first work piece 14 and the second work piece16 in a third DM process. The first, second, and third DM processes maybe formed at the same or different worksites. For example, the additivemanufacturing system 10 may build up the first work piece 14 at a firstworksite, the additive manufacturing system 10 may build up the secondwork piece 16 at a second worksite, and the additive manufacturingsystem 10 may form the part (e.g., joint) at yet a third worksite. Insome embodiments, the additive manufacturing system 10 may produce viaadditive manufacturing one or more work pieces and the respective part12 (e.g., anchor, joint) therebetween. In some embodiments, the additivemanufacturing system 10 may produce the part 12 at the first end 70 ofthe first work piece 14 without connecting the open end of the part 12to the second work piece 16. The additive manufacturing system 10 mayform the part 12 with the open end of the part 12 configured to later beconnected (e.g., via welding) to the second work piece 16. In this way,the additive manufacturing system 10 may facilitate connecting the firstwork piece 14 of a first material to the second work piece 16 of adifferent second material.

The additive manufacturing system may be utilized to form metalliclayers for various purposes, including joining dissimilar materials. Insome embodiments, the additive manufacturing system may form acorrosion-resistive and/or wear-resistive overlay on a fabricatedcomponent. The additive manufacturing system may have the flexibility toadapt metallic components with layers for various geometries and/or toprovide metallurgical features for a desired performance. Moreover, theadditive manufacturing system may be utilized to build up (e.g., print)components with one or more anchoring materials in a process similar towelding.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1. An additive manufacturing system, comprising: an additivemanufacturing tool configured to receive one or more metallic anchoringmaterials; a power source configured to provide DC or AC power to theone or more metallic anchoring materials to melt the one or moremetallic anchoring materials into a plurality of droplets, the additivemanufacturing tool being configured to deposit the plurality ofdroplets; and a controller configured to control the additivemanufacturing tool or the power source to fasten a first base materialto a second base material via the plurality of droplets by: controllingthe additive manufacturing tool or the power source to apply theplurality of droplets to a first base material to build up a partcoupled to the first base material, and controlling the additivemanufacturing tool or the power source to apply the plurality ofdroplets to the part to complete the part without melting the secondbase material, thereby securing the second base material from movementin one or more directions relative to the first base material.
 2. Thesystem of claim 1, wherein the plurality of droplets are applied to thefirst base material through a recess in the second base material.
 3. Thesystem of claim 1, wherein completing the part comprises controlling theadditive manufacturing tool or the power source to form a cap on thepart that resists separation of the first base material from the secondbase material.
 4. The system of claim 1, wherein the first base materialcomprises a different material than the second base material.
 5. Thesystem of claim 1, further comprising a position sensor configured tomeasure a position of the additive manufacturing tool relative to thefirst base material, second base material, or part, wherein thecontroller is configured to control the additive manufacturing tool orthe power source based on the position measured by the position sensor.6. The system of claim 1, further comprising a temperature sensor,wherein the temperature sensor is configured to measure a temperature ofthe one or more metallic anchoring materials, the part, the first basematerial, or the second base material, and wherein the controller isconfigured to control the additive manufacturing tool or the powersource based on the temperature measured by the temperature sensor. 7.The system of claim 1, wherein the controller is configured to control adeposition location of each droplet of the plurality of droplets via arobotic system configured to move the additive manufacturing toolrelative to the part.
 8. The system of claim 1, wherein the additivemanufacturing tool further comprises a heater configured to preheat theone or more metallic anchoring materials before the one or more metallicanchoring materials are melted into the plurality of droplets.
 9. Thesystem of claim 1, further comprising one or more feeders configured tosupply the one or more metallic anchoring materials to the additivemanufacturing tool.
 10. The system of claim 1, wherein the controller isconfigured to control the power source to provide the electrical powerin the form of a pulsed welding waveform, a short circuit weldingwaveform, or a controlled short circuit welding waveform.
 11. A methodof additively forming a part, comprising: generating an AC or DCelectrical power at a power source; melting one or more metallicanchoring materials into a plurality of droplets at an additivemanufacturing tool using the electrical power; controlling, via acontroller, the additive manufacturing tool or the power source to applythe plurality of droplets to a first base material to build up a partcoupled to the first base material; and controlling the additivemanufacturing tool or the power source to apply the plurality ofdroplets to the part to complete the part without melting the secondbase material, thereby securing the second base material from movementin one or more directions relative to the first base material.
 12. Themethod of claim 11, wherein the plurality of droplets are applied to thefirst base material through a recess in the second base material. 13.The method of claim 11, wherein completing the part comprisescontrolling the additive manufacturing tool or the power source to forma cap on the part that resists separation of the first base materialfrom the second base material.
 14. The method of claim 11, wherein thefirst base material comprises a different material than the second basematerial.
 15. The method of claim 11, further comprising: measuring aposition of the additive manufacturing tool relative to the part, thefirst base material, or the second base material; measuring atemperature of the part, the first base material, or the second basematerial; determining a deposition rate based on the temperature; andapplying the plurality of droplets, via the additive manufacturing tool,at the deposition rate.
 16. The method of claim 15, wherein theelectrical power is generated based on the position and the depositionrate.
 17. The method of claim 11, further comprising: measuring aposition of the additive manufacturing tool relative to the part, thefirst base material, or the second base material; measuring atemperature of the part, the first base material, or the second basematerial; determining a target temperature of a droplet based on thetemperature; and generating the electrical power based on the targettemperature and the position.
 18. The method of claim 11, furthercomprising preheating, via a heater, the one or more metallic anchoringmaterials, the first base material, or the second base material.
 19. Themethod of claim 11, further comprising preheating at the additivemanufacturing tool, via a heater, the one or more metallic anchoringmaterials before the one or more metallic anchoring materials aremelted.
 20. The method of claim 11, wherein the electrical powercomprises a pulsed welding waveform, a short circuit welding waveform,or a controlled short circuit welding waveform.